Semiconductor device and method of manufacturing a semiconductor device

ABSTRACT

A packaged electronic device structure includes a substrate having a major surface. A semiconductor device is connected to the major surface of the substrate, the semiconductor device having a first major surface, a second major surface opposite to the first major surface, and a side surface extending between the first major surface and the second major surface. A package body encapsulates a portion of the semiconductor device, wherein the side surface of the semiconductor device is exposed through a side surface of the package body. In some examples, the side surface of the semiconductor device is an active surface. In some examples, the package body comprises a molded structure that contacts and overlaps the first major surface of the semiconductor device.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of co-pending U.S. patent applicationSer. No. 16/283,752 filed on Feb. 23, 2019, and issued as U.S. Pat. No.10,644,479 on May 5, 2020, which is expressly incorporated by referenceherein and priority thereto is hereby claimed.

BACKGROUND OF THE DISCLOSURE

The present disclosure relates, in general, to electronics, and moreparticularly, to semiconductor packages, structures thereof, and methodsof forming semiconductor packages.

Prior semiconductor packages and methods for forming semiconductorpackages are inadequate, for example resulting in excess cost, poorthermal performance, decreased reliability, relatively low performance,or package sizes that are too large. More particularly, some packagedsemiconductor devices include semiconductor devices, such as sensor oroptical devices that require exposing one or more side surfaces of thedevices, which are active surfaces, to the outside of the package. Suchdevices include, for example, laser devices that can be incorporatedinto light detection and ranging (“LIDAR”) systems. Previous methodsused to produce packaged semiconductor devices with one or more sidesurfaces of the semiconductor device exposed have yielded poor resultswith problems including damage to the semiconductor device andconductive interconnects, such as wire bonds. In addition, theconductive interconnects have been left exposed to the environmentthrough the open side surface or within the cavity of the packageresulting in reliability issues. Further limitations and disadvantagesof conventional and traditional approaches will become apparent to oneof ordinary skill in the art, through comparison of such approaches withthe present disclosure and reference to the drawings.

Accordingly, it is desirable to have a package structure and a methodthat provides a packaged electronic device that overcomes theshortcomings of the prior art. It is also desirable for the structureand method to be easily incorporated into manufacturing flows,accommodate multiple die interconnect schemes, and to be cost effective.

BRIEF SUMMARY

The present description includes, among other features, a packagedelectronic device structure and associated methods that comprise anelectronic device having an active side surface exposed in side surfaceof an enclosure structure. In some examples, the enclosure structurecomprises a molded package body. In other examples, the enclosurestructure comprises a lid structure. In both structures, elements, suchas conductive interconnect structures are protected from the environmentto improve reliability compared to previous devices. The packagedelectronic device structures can accommodate multiple die interconnectsschemes. The associated methods can be incorporated into standardmanufacturing flows to provide cost effective integration.

More particularly, in one example, a method for forming a packagedelectronic device structure includes providing a substrate having amajor surface. The method includes attaching a first device to the majorsurface of the substrate. The method includes forming a package bodyencapsulating a portion of the first device, wherein a side surface ofthe first device is exposed outside of the package body. In someexamples, attaching the first device comprises attaching a semiconductordevice having an emitter region as part of the side surface of thesemiconductor device exposed outside of the package body. In someexamples, the method includes attaching a second device to the majorsurface spaced apart from the first device to provide a gap between thefirst device and the second device; and forming the package bodycomprises forming the package body such that the gap is devoid of thepackage body.

In another example, a packaged electronic device structure includes asubstrate having a major surface. A semiconductor device is connected tothe major surface of the substrate, the semiconductor device having afirst major surface, a second major surface opposite to the first majorsurface, and a side surface extending between the first major surfaceand the second major surface. A package body encapsulates a portion ofthe semiconductor device, wherein the side surface of the semiconductordevice is exposed through a side surface of the package body. In someexamples, the package body comprises a molded structure that contactsand overlaps the first major surface of the semiconductor device. Inother examples, the structure further includes a conductive interconnectstructure electrically connecting the semiconductor device to thesubstrate, and the package body encapsulates the conductive interconnectstructure.

In a further example, a method for forming a packaged electronic devicestructure includes providing a substrate having a major surface. Themethod includes attaching a semiconductor device to the major surface ofthe substrate, the semiconductor device having a first major surface, asecond major surface opposite to the first major surface, and a sidesurface extending between the first major surface and the second majorsurface. The method includes electrically connecting the semiconductordevice to the substrate with a conductive interconnect structure. Themethod includes covering the conductive interconnect structure and atleast a portion of the first major surface of the semiconductor devicewith a protective material. The method includes attaching a lidstructure to the substrate, the lid structure comprising sides, a top,and an opening, wherein the side surface of the semiconductor device isexposed outside of the lid structure through the opening. In someexamples, the substrate and the lid structure comprise similarmaterials. In other examples, attaching the lid structure includesattaching the sides to the major surface of the substrate; and attachingthe top to the sides; and the method further includes removing a portionof the lid structure to provide the opening after the lid structure isattached to the substrate.

Other examples are included in the present disclosure. Such examples maybe found in the figures, in the claims, and/or in the description of thepresent disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a cross-sectional view of an example packagedelectronic device of the present description;

FIG. 2 is a flow chart of an example method of forming a packagedelectronic device of the present description;

FIGS. 3-7 illustrate partial cross-sectional views of the packagedelectronic device of FIG. 1 at various stages of manufacture inaccordance with the present description;

FIG. 8 illustrates a partial cross-sectional view of an example packagedelectronic devices of the present description at an intermediate stageof manufacture;

FIG. 9 illustrates a cross-sectional view of an example packagedelectronic device of the present description;

FIG. 10 is a flow chart of an example method of forming a packagedelectronic device of the present description;

FIGS. 11-15 illustrate partial cross-sectional views of the packagedelectronic device of FIG. 9 at various stages of manufacture inaccordance with the present description; and

FIG. 16 illustrates a cross-sectional view of an example packagedelectronic device of the present description.

For simplicity and clarity of the illustration, elements in the figuresare not necessarily drawn to scale, and the same reference numbers indifferent figures denote the same elements. Additionally, descriptionsand details of well-known steps and elements are omitted for simplicityof the description. As used herein, the term and/or includes any and allcombinations of one or more of the associated listed items. In addition,the terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting of thedisclosure. As used herein, the singular forms are intended to includethe plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms comprises,comprising, includes, and/or including, when used in this specification,specify the presence of stated features, numbers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, numbers, steps, operations,elements, components, and/or groups thereof. It will be understood that,although the terms first, second, etc. may be used herein to describevarious members, elements, regions, layers and/or sections, thesemembers, elements, regions, layers and/or sections should not be limitedby these terms. These terms are only used to distinguish one member,element, region, layer and/or section from another. Thus, for example, afirst member, a first element, a first region, a first layer and/or afirst section discussed below could be termed a second member, a secondelement, a second region, a second layer and/or a second section withoutdeparting from the teachings of the present disclosure. Reference to“one example” or “an example” means that a particular feature, structureor characteristic described in connection with the embodiment isincluded in at least one example of the present invention. Thus,appearances of the phrases “in one example” or “in an example” invarious places throughout this specification are not necessarily allreferring to the same example, but in some cases it may. Furthermore,the particular features, structures or characteristics may be combinedin any suitable manner, as would be apparent to one of ordinary skill inthe art, in one or more example embodiments. Additionally, the termwhile means a certain action occurs at least within some portion of aduration of the initiating action. The use of word about, approximatelyor substantially means a value of an element is expected to be close toa state value or position. However, as is well known in the art thereare always minor variances preventing values or positions from beingexactly stated. Unless specified otherwise, as used herein the word overor on includes orientations, placements, or relations where thespecified elements can be in direct or indirect physical contact. It isfurther understood that the examples illustrated and describedhereinafter suitably may have examples and/or may be practiced in theabsence of any element that is not specifically disclosed herein.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a cross-sectional view of an example packagedelectronic device structure 10, such as a packaged semiconductor device10 in accordance with the present description. The example isillustrated as a land grid array packaged semiconductor devicestructure, but the description is not limited to this type of packageand is suitable for other types of packages. In the example illustratedin FIG. 1, packaged electronic device structure 10 comprises a substrate11, an electronic component 16, such as a semiconductor device 16, anattachment material 17, conductive interconnect structure(s) 21, and anenclosure structure, such as a package body 36. In accordance with thepresent description and the present example, semiconductor device 16includes a side surface 14, which can be an active surface that isexposed to through an opening or passage in or through a side surface 32of enclosure structure 36.

Conductive interconnect structures 21, substrate 11, attachment material17, and package body 36 can be referred to as a semiconductor package190, and semiconductor package 190 can provide protection for portionssemiconductor device 16 from external elements and/or environmentalexposure. In addition, semiconductor package 190 can provide electricalcoupling from external electrical components (not shown) to conductiveinterconnect structures 21 and semiconductor device 16.

Substrate 11 can be selected from common circuit boards (for example,rigid circuit boards and flexible circuit boards), multi-layersubstrates, laminate substrates, core substrates with build-up layers,coreless substrates, ceramic substrates, lead frame substrates, moldedlead frame substrates, or similar substrates as known to one of ordinaryskill in the art. In this regard, the present description is notintended to be limited to any particular type of substrate 11. By way ofexample and not by way of limitation, the substrate 11 may include aninsulating structure 114 having opposed, generally planar top and bottomsurfaces. It is understood that multiple insulating layer portions canbe used to provide insulating structure 114. An electrically conductivepattern 112 or conductive pattern layer 112 can be disposed adjacent tothe top surface of insulating structure 114, and conductive lands 113can be disposed adjacent to the bottom surface of insulating structure114.

In some examples, conductive pattern 112 and conductive lands 113 areelectrically interconnected to each other in a prescribed pattern orarrangement using conductive interconnect paths 111, defined by portionsof one or more conductive layers, that extend through the insulatingstructure 114 from conductive pattern 112 to conductive lands 113.Conductive pattern 112, conductive lands 113, and conductiveinterconnect layers 111 comprises conductive materials, such as one ormore metals. In some examples, conductive pattern 112, conductive lands113, and conductive interconnect layers 111 comprise copper. In someexamples, a solder mask 115 or protective layer 115 can be providedadjacent to at least portions of conductive pattern 112 and the topsurface of insulating structure 114. In addition, in some examples asolder mask 116 or protective layer 116 can be provided on at leastportions of the lands 113 and the bottom surface of insulating structure114. The solder mask 115 is used to protect portions of conductivepattern 112 that would otherwise be susceptible to electrical shortingissues. The solder mask 116 is used to protect portions of the lands 113that would otherwise be exposed to the ambient environment.

Semiconductor device 16 includes a first major surface 18 where activedevices and/or passive devices typically are provided, an opposingsecond major surface 19, and a side surface 14 that extends generallyperpendicularly between first major surface 18 and second major surface19. Major surface 19 of semiconductor device 16 can be attached tosubstrate 11 in a device active region up (or die up) configurationusing attachment material 17, which can comprise a thermally conductiveand electrically conductive material, or a thermally conductive andelectrically non-conductive material. In some examples, attachmentmaterial 17 comprises an epoxy-type die attach material. In otherexamples, attachment material 17 can be a solder material, such as asolder paste or other materials as known to one of ordinary skill in theart. Attachment material 17 typically functions to both providemechanical fixation of semiconductor device 16 to substrate 11 and todissipate heat generated by semiconductor device 16. In some examples,attachment material 17 can provide an electrical path from substrate 11to semiconductor device 16.

In some examples, semiconductor device 16 includes bond pads 24 disposedadjacent to major surface 18. In some examples, conductive interconnectstructures 21 electrically connect bonds pads 24 to portions ofconductive pattern 112. In the present example, conductive interconnectstructures 21 comprise conductive wires, and can be provided using wirebonding techniques with wire comprising copper, gold, aluminum, or otherconductive materials as known to one of ordinary skill in the art.Conductive interconnect structures 21 function to transmit electricalsignals to and from semiconductor device 16. In other examples,semiconductor device 16 can be attached to a portion of conductivepattern 112 with different conductive interconnect structures, such asconductive bumps in a flip-chip configuration with major surface 18facing substrate 11.

In the present example, conductive lands 113 can be configured todirectly connect or attach to a next level of assembly, such as aprinted circuit board. In some examples, conductive interconnectstructures can be attached to conductive lands 113 in a ball-grid array(BGA) configuration, and can comprise conductive materials, such assolder balls, solder bumps, copper bumps, nickel gold bumps, or similarmaterials as known to one of ordinary skill in the art.

In some examples, semiconductor device 16 is an optical device, such asa laser device that includes an emitter region 161 disposed proximate toside surface 14 of semiconductor device 16. It is understood thatemitter region 161 may be disposed entirely within or partially withinsemiconductor device 16. Examples of such laser devices can include edgeemitting laser (EEL) devices. In other examples, semiconductor device 16is an integrated circuit device, a power semiconductor device, anoptical device, any type of sensor device, or other devices as known toone of ordinary skill in the art particularly devices requiring that oneor more side surfaces of the device be exposed in a side surface (e.g.,side surface 32) of package body 36. One of ordinary skill in the artwill appreciate that semiconductor device 16 is illustrated insimplified form, and may further include multiple diffused regions,multiple conductive layers, and multiple dielectric layers.

Packaged semiconductor device 10 further includes enclosure structure36, such as package body 36 that covers or encapsulates conductiveinterconnect structures 21, portions of semiconductor die 16, conductivepattern 112, and portions of substrate 11. In accordance with thepresent example, package body 36 is provided so that side surface 14 ofsemiconductor device 16 exposed to the outside of packaged semiconductordevice 10. In some examples, package body 36 does not extend along theside surface of substrate 11 or along the bottom surface of substrate11.

In some examples, package body 36 can be polymer based compositematerial, such as epoxy resin with filler, epoxy acrylate with filler,or polymer with proper filler. Package body 36 comprises anon-conductive and environmentally protective material that protectsconductive interconnect structures 21 and portions of semiconductordevice 16 from external elements and contaminants. Package body 36 maybe formed using paste printing, compressive molding, transfer molding,over-molding, liquid encapsulant molding, vacuum lamination, othersuitable applicator, or other processes as known to those of skill inthe art. In some embodiments, package body 36 is an epoxy mold compound(“EMC”) and can be formed using transfer or injection moldingtechniques.

In accordance with the present example, the configuration of packagebody 36 facilitates exposing side surface 14 of semiconductor device 16including, for example, emitter region 161 to the outside of packagebody 36 through side surface 32. In some examples, side surface 32comprises a sloped or tapered shape 320 as generally illustrated in FIG.1, which can provide for a more efficient and reliable manufacturingprocess. In addition, package body 36 functions to protect conductiveinterconnect structures 21, portions of semiconductor device 16including bond pads 24, and portions of conductive pattern 112 therebyimproving reliability over previous packaged devices where some or allof these features are exposed to the environment. In some examples,package body 36 contacts semiconductor device 16 and laterally overlapsmore than 50% of major surface 18 of semiconductor device 16. In otherexamples, package body 36 contacts semiconductor device 16 and laterallyoverlaps more than 75% of major surface 18.

FIG. 2 is a flow chart illustrating an example method 100 formanufacturing packaged electronic devices, such as packagedsemiconductor devices 10 in accordance with the present description. Ina Block S110 of method 100, a plurality of devices and a substratestructure are provided. The plurality of devices can include one or moresemiconductor devices as well as other devices. In a Block S120 ofmethod 100, the plurality of devices, which includes a first device anda second device, are attached to a major surface of the substratestructure so that the first device and the second device are laterallyseparated to provide gap or cavity between them.

FIGS. 3 and 4 illustrate partial cross-sectional views of packagedsemiconductor device 10 at stages of manufacture, and further illustratean example of Block S110 and Block S120 of method 100. In the presentexample, the plurality of devices provided can include one or moresemiconductor devices, such as semiconductor devices 16 (or variationsthereof) as well as other devices, such as a dummy device 117 (orvariations thereof), which is illustrated in FIG. 4. The substratestructure provided can be similar to substrate 11 of FIG. 1 (orvariations thereof or other substrate structures). In one example, thefirst device can be one of semiconductor devices 16, which is attachedto a surface of substrate 11 with attachment material 17 as part ofBlock S120. As described previously, attachment material 17 can be anepoxy-type die attach material, which can be deposited onto one or morepredetermined portions of substrate 11. In other examples, attachmentmaterial 17 can comprise a solder material or other materials as knownto one of ordinary skill in the art. In the present example,semiconductor device 16 comprises a sensor device having a side surface14 that is an active surface or active part of semiconductor device 16.By way of example, semiconductor device 16 is a laser device havingemitter region 161 disposed on, within, or as part of side surface 14.In some examples, the attachment material 17 can be cured aftersemiconductor device 16 is placed into contact with attachment material17.

In the present example, the second device comprises dummy device 117 asillustrated in FIG. 4, which can be an unprocessed chip or diecomprising a semiconductor material. In some examples, dummy device 117has a similar thickness to semiconductor device 16, but dummy device 117can have a smaller area than that of semiconductor device 16 to consumeless area on substrate 11. In one example, dummy device 117 is anunprocessed or minimally processed silicon die. In Block S120, thesecond device, such as dummy device 117 is attached to substrate 11. Insome examples, attachment material 17 (or other materials) can be usedto attach dummy device 117 to substrate 11. In accordance with thepresent description, semiconductor device 16 and dummy device 117 aredisposed on substrate 11 so as to be laterally spaced apart from eachother to provide a gap 41, cavity 41, or lateral space 41 between them.In the present example, dummy device 117 has a side surface 214 thatdirectly faces or overlaps side surface 14 of semiconductor device 16 todefine at least a portion of gap 41.

Method 100 also includes a Block S130, which comprises electricallyconnecting at least the first device to the substrate structure. FIG. 5illustrates a partial cross-sectional view of packaged semiconductordevice 10 at a further stage of manufacture and further illustrates anexample of Block S130 of method 100. In some examples, the step ofelectrically connecting can be done using conductive wires configured asconductive interconnect structures 21, which can be provided using wirebonding techniques. In some examples, conductive interconnect structures21 are attached to bond pads 24 disposed adjacent to major surface 18 ofsemiconductor device 16 and to conductive pattern 112. In otherexamples, semiconductor device 16 can be attached to substrate 11 in aflip-chip configuration with the conductive interconnect structurescomprising conductive bump structures, such as solder bumps. In thisalternative configuration, it is not necessary to attach dummy die 117to substrate 11 in a flip-chip configuration, but it can be attached ina flip-chip configuration as a matter of design choice. That is, dummydie 117 can still be attached to substrate 11 with attachment material17 when semiconductor device is attached to substrate 11 with conductivebumps. In this example, semiconductor device 16 and dummy die 117 areattached to substrate 11 using different means. When flip-chipinterconnects are used, the step of attaching the first device andelectrically connecting the first device to the substrate structure canbe a combined step. In some examples, an optical inspection step can bedone at this point in the manufacturing process to ensure that thesub-assembly is properly formed.

At this stage of manufacture, a sub-assembly 51A is provided; and it isunderstood that although only one semiconductor device 16 and one dummydevice 117 is illustrated, sub-assembly 51A can include many (i.e., morethan one) semiconductor devices 16 and many (i.e., more than one) dummydevices 117. It is further understood that the order in whichsemiconductor device 16 and dummy devices 117 are attached to substrate11 can be different than the sequence illustrated. In addition,conductive interconnect structure 21 can be attached to semiconductordevice 16 and conductive pattern layer 112 before dummy device 117 isattached to substrate 11.

Method 100 further includes a Block S140, which comprises using ablocking structure to enclose or cover the gap, and thereafter forming apackage body to encapsulate portions of at least the first device whileleaving at least one side surface of the first device exposed in the gapand not covered by the package body. In some examples, at least portionsof the second device are encapsulated by the package body while at leastone side surface of the second device is exposed in the gap and notcovered by the package body. FIG. 6 illustrates a partialcross-sectional view of sub-assembly 51A after further processing inaccordance with Block S140 of method 100. In some examples, sub-assembly51A is placed in molding apparatus, which includes a support structure(not shown) for holding substrate 11 and a blocking device, such a moldchase tool 61 having a protruding portion 620 configured to enclose orcover gap 41 between semiconductor device 16 and dummy device 117. Insome examples, a film assisted molding technique is used with BlockS140. For example, a protective film 63 is disposed on an outer surface610 of mold chase tool 61. In some examples, protective film 63comprises a plastic material or similar materials as known to one ofordinary skill in the art.

In some examples, portion 620 of mold chase tool 61 has width wider thangap 41 so that portion 620 completely extends across gap 41 and overlapsportions of major surface 18 of semiconductor device 16 and a portion ofdummy device 117. The amount of overlap determines where package body 36terminates along major surface 18 of semiconductor device 16. In someexamples portion 620 with protective film 63 is brought into contactwith semiconductor device 16, dummy device 117, and a portion ofsubstrate 11 (not shown) to form a seal around gap 41. Next, packagebody 36 is provided using molding techniques. In accordance with thepresent example, package body 36 is provided to encapsulate or coverportions of semiconductor device 16 and dummy device 117 while sidesurface 14 of semiconductor device 16 and side surface 214 of dummydevice 117 are left exposed in gap 41 and not covered by package body36. That is, at least side surface 14 of semiconductor device 16 is notcovered by package body 36 and is exposed through an opening or passagein side surface 32 of package body 36 as illustrated in FIGS. 1 and 7.

In some examples, that portion of substrate 11 that is disposed withingap 41 is not covered by package body 36. In some examples, the shape orcontour of portion 620 defines the shape of side surface 32 of packagebody 36. Such shapes can include, for example, sloped shape 320 asillustrated in FIG. 1, or other shapes. In other examples, otherblocking structure can be used, such as masking structures that enclosegap 41 during the molding process.

Block S150 of method 100 comprises separating the first device from thesecond device through the gap to provide at least one packagedsemiconductor device with a side surface exposed through a side surfaceof the package body. In some examples, a separation process (representedby arrow 71), such as a sawing process or a laser cutting process isused to singulate or physically separate subassembly 51A into individualpackaged semiconductor devices, such as packaged semiconductor devices10. In some examples, the width of gap 41 is selected to provide a safeoperating area 72 to accommodate the method used to separate substrate11 without damaging semiconductor device 16. In other examples, portions(or all of) of dummy device 117 can be removed during the singulationprocess to allow for a narrower safe operating area 71.

In accordance with the present description, method 100 provides packagedsemiconductor device 10 having semiconductor device 16 partiallyencapsulated by package body 36, which protect portions of semiconductordevice 16 and conductive interconnect structures 21 while providing sidesurface 14, which is an active surface of semiconductor device 16,exposed through a side surface 32 of package body 36.

FIG. 8 illustrates a partial cross-sectional view of an example ofpackaged electronic devices 10 at an intermediate stage of fabrication.In the present example, a sub-assembly 51B has a second device thatcomprises another semiconductor device 16B instead of dummy device 117.In some examples, semiconductor device 16B is attached to substrate 11so that side surface 14B, which can be an active surface including anemitter region 161B, of semiconductor device 16B directly faces sidesurface 14 of semiconductor device 16. During the molding process, theblocking structure overlaps a portion of major surface 18 ofsemiconductor device 16B.

FIG. 9 illustrates a cross-sectional view of an example packagedelectronic device structure 90, such as a packaged semiconductor device90 in accordance with the present description. Packaged semiconductordevice 90 is another example of a semiconductor package 190 inaccordance with the present description. Packaged semiconductor device90 is similar to packaged semiconductor device 10 and only thedifferences will be described hereinafter. Packaged semiconductor device90 comprises a different enclosure structure compared to packagedsemiconductor device 10. More particularly, packaged semiconductordevice 90 comprises a lid structure 360, which includes sides 361 orside walls 361 and a top 363 attached to sides 361 with an attachmentmaterial 364. In some examples, sides 361 are attached to substrate 11using an attachment material 367. Attachment materials 364 and 367 cancomprise electrically conducting and thermally conducting materials,electrically insulating and thermally conductive materials, soldermaterials, epoxy type adhesive materials, conductive pastes, or othermaterials as known to one of ordinary skill in the art.

In some examples, lid structure 360 comprises a laminate material andcan be a material or materials similar to those used to providesubstrate 11. In some examples, lid structure 360 comprises aninsulating structure. In other examples, lid structure 360 comprises aconductive material or a combination of conductive material(s) andinsulating material(s). When lid structure 360 includes a conductivematerial, lid structure 360 can be configured as a shielding structurefor semiconductor device 16, and, in some examples, can be electricallygrounded through conductive pattern layer 112, conductive interconnectpaths 111, and conductive lands 113 as generally illustrated in FIG. 9.In some examples, lid structure 360 comprises multiple parts asgenerally illustrated in FIG. 9. In other examples, lid structure 360comprises a single-piece configuration as generally illustrated in FIG.16.

In some examples, sides 361 have a height that places top 363 safelyabove conductive interconnect structures 21, which in the presentexample are protected or enclosed with a protective material 211.Protective material 211 can comprise a protective gel, such as apolymeric material. In some examples, protective material 211 comprisesa silicone gel. Protective material 211 functions to seal, encapsulateand protect conductive interconnect structures 21 and a portion ofsemiconductor device 16 including, for example, bond pads 24. This is animprovement over prior devices where the conductive interconnectstructures are left exposed to the environment, which can result inreliability problems.

In accordance with the present description, lid structure 360 isprovided with an opening 368, which exposes active side surface 14including emitter region 161 of semiconductor device 16 to the outsideof lid structure 360. In some examples, top 363 is supported by threesides 361, which are disposed around a perimeter of substrate 11. Inother examples, top 363 is supported by at least two sides 361. Sides361 can be configured to follow the general shape of semiconductordevice 16. In other examples, sides 361 can be configured to have adifferent shape than semiconductor device 16.

FIG. 10 is a flow chart illustrating an example method 200 formanufacturing packaged electronic device structures, such as packagedsemiconductor devices 90 in accordance with the present description.FIGS. 11-15 illustrate partial cross-sectional views of packagedsemiconductor device 90 at various stages of manufacture in accordancewith method 200. In a Block S210, a first device is attached to a majorsurface of a substrate structure.

FIG. 11 illustrates a partial cross-sectional view of packagedsemiconductor device 90 at an early stage of manufacture aftercompletion of Block S210. In some examples, the substrate structure canbe similar to substrate 11 of FIG. 9 (or variations thereof or othertypes of substrates). In some examples, the first device can besemiconductor device 16 (or variations thereof) as well as otherdevices. As previously described, the first device, such assemiconductor device 16 can be attached to substrate 11 with attachmentmaterial 17. In some examples, the attachment material 17 can be curedafter semiconductor device 16 is placed into contact with attachmentmaterial 17.

Method 200 also includes a Block S220 comprising electrically connectingthe first device to the substrate structure with a conductiveinterconnect structure. FIG. 12 illustrates a partial cross-sectionalview of packaged semiconductor device 90 after completion of Block S220in accordance with one example. In some examples, the step ofelectrically connecting can be done using conductive wires configured asconductive interconnect structures 21, which can be provided using wirebonding techniques. In some examples, conductive interconnect structures21 are attached to bond pads 24 disposed adjacent to major surface 18 ofsemiconductor device 16 and to conductive pattern 112. In otherexamples, semiconductor device 16 can be attached to substrate 11 in aflip-chip configuration with the conductive interconnect structurescomprising conductive bump structures, such as solder bumps. In theflip-chip configuration, Blocks S210 and S220 can be combined into asingle step.

Method 200 further includes a Block S230 comprising providing aprotective material covering the conductive interconnect structures. Theprotective material can be similar to protective material 211 (orvariations thereof). FIG. 13 illustrates a partial cross-sectional viewof packaged semiconductor device 90 after completion of Block S230 inaccordance with one example. In some examples, protective material 211is provided to cover conductive interconnect structure 21 and cancomprise a protective gel material as described previously. A dispensingprocess can be used to form protective material 211. In some examples,protective material 211 further covers part of semiconductor device 16including bond pads 24 and further covers a portion of conductivepattern layer 112 where conductive interconnect structure 21 isattached. In some examples, protective material 211 can be cured afterit is formed. In some examples, an optical inspection step can be doneat this point in the manufacturing process to ensure that thesub-assembly is properly formed.

Method 200 includes a Block S240 comprising attaching an enclosurestructure to the substrate structure, the enclosure structure includinga sidewall structure. The enclosure structure can be similar to lidstructure 360 (or variations thereof). FIG. 14 illustrates packagedsemiconductor device 90 after completion of Block S240 in accordancewith one example. When lid structure 360 comprises multiple parts, sides361 can be attached first to substrate 11 using attachment material 367.In some examples, one or more sides 361 are attached to conductivepattern layer 112. In one example, attachment material 367 comprises anepoxy-type attachment material. In other examples, attachment material367 can be a solder material.

After sides 361 are attached, top 363 can be attached to sides 361 usingattachment material 364, which can be an epoxy-type attachment materialor a solder material. When lid structure 360 comprises a single piece,sides 361 integral with top 363 can be attached to substrate 11 withattachment material 367. In other examples, sides 361 can be attached totop 363 with attachment material 364 before sides 361 are attached tosubstrate 11 with attachment material 367. In some examples, attachmentmaterials 364 and 367 are cured after sides 361 and top 363 areattached. After Block S140, lid structure 360 can completely enclosesemiconductor device 16, conductive interconnect structure 21, andprotective material 211. In some examples, after lid structure 360 isattached, top 363 can be marked with identification information. Lasermarking can be used for providing the identification information on top363. With the present configuration, top 363 is supported on all edgesby sides 361, which can provide a more stable structure for the lasermarking step.

Method 200 further includes a Block S250 comprising removing a portionof the enclosure structure including a portion of the sidewall structureto provide an opening that exposes a side surface of the first device tothe outside of the enclosure structure. The removal step can remove aportion of lid structure 360 (or variations thereof) including a portionof a side 361. FIG. 15 illustrates a partial cross-sectional view ofpackaged semiconductor device 90 in accordance with an example of BlockS250. In some examples, a separation process (represented by arrow 71),such as a sawing process or a laser cutting process is used to singulateor physically separate a portion of lid structure 360 and substrate 11at selected locations (represented by vertical dashed line 172) toexpose side surface 14 of semiconductor device 16 through opening 368 oflid structure 360 as generally illustrated in FIG. 9. The location ofthe separation process is selected so as to not damage semiconductordevice 16 during this step.

In accordance with the present description, method 200 provides packagedsemiconductor device 90 having protective material 211 coveringconductive interconnect structure 21 and semiconductor device 16 withside surface 14 (which is an active surface) exposed through opening 368in lid structure 360. In addition, when lid structure 360 and substrate11 comprise similar materials, a packaged semiconductor device withreduced stress can be provided.

FIG. 16 illustrates a cross-sectional view of an example packagedelectronic device structure 160, such as a packaged semiconductor device160 in accordance with the present description. Packaged semiconductordevice 160 is another example of a semiconductor package 190 inaccordance with the present description. Packaged semiconductor device160 is similar to packaged semiconductor device 90, and only thedifferences will be described hereinafter. Lid structure 360 illustratedin FIG. 16 comprises a single piece construction where sides 361 areintegral with top 363. In addition, protective material 211 is providedso as to cover most of semiconductor device 16 while leaving sidesurface 14 uncovered and exposed through opening 368. In other examples,a lens structure can be provided within opening 368. In semiconductordevice 160, protective material 211 can be provided before or after lidstructure 360 is attached to substrate 11. In some examples, lidstructure 360 physically contacts protective material 211. In otherexamples, one or more spaces or gaps may be provided between protectivematerial 211 and lid structure 360 or portions thereof (e.g., a spacebetween top 363 and protective material 211 and/or a space between sides361 and protective material 211).

In summary, a packaged electronic device structure and associatedmethods have been described that comprise an electronic device having anactive side surface exposed in a side surface of an enclosure structure.In some examples, the enclosure structure comprises a molded packagebody. In other examples, the enclosure structure comprises a lidstructure. In both structures, elements, such as conductive interconnectstructures are protected from the environment to improve reliabilitycompared to previous devices. The packaged electronic device structurescan accommodate multiple die interconnects schemes. The associatedmethods can be incorporated into standard manufacturing flows to providecost effective integration.

While the subject matter of the invention is described with specificexample steps and example embodiments, the foregoing drawings anddescriptions thereof depict only typical examples of the subject matter,and are not therefore to be considered limiting of its scope. It isevident that many alternatives and variations will be apparent to thoseskilled in the art. By way of example, multiple electronic devices canbe attached to a pad in side-by-side configurations, in stackedconfigurations, combinations thereof, or other configurations known tothose skilled in the art. In addition, the lid structure for packagedsemiconductor device 90 can be provided with a pre-existing openingbefore it is attached to the substrate structure.

As the claims hereinafter reflect, inventive aspects may lie in lessthan all features of a single foregoing disclosed example. Thus, thehereinafter expressed claims are hereby expressly incorporated into thisDetailed Description of the Drawings, with each claim standing on itsown as a separate example of the invention. Furthermore, while someexamples described herein include some, but not other features includedin other examples, combinations of features of different examples aremeant to be within the scope of the invention and meant to formdifferent examples as would be understood by those skilled in the art.

What is claimed is:
 1. A packaged semiconductor device, comprising: asubstrate having a first substrate surface; a semiconductor deviceconnected to the first substrate surface, the semiconductor devicehaving a first major surface, a second major surface opposite to thefirst major surface, and a side surface extending between the firstmajor surface and the second major surface, wherein the semiconductordevice comprises an optical device and the side surface of thesemiconductor device includes an emitter region, and wherein: the sidesurface comprises a first side proximate to a first outer side surfaceof the substrate and a second side distal the first outer side surfaceof the substrate; and the first side includes the emitter region; aconductive interconnect structure electrically connecting thesemiconductor device to the substrate; and an encapsulated package bodycovering at least a portion of the first substrate surface and coveringthe semiconductor device, wherein the emitter region is exposed outsideof the encapsulated package body, and wherein: the encapsulated packagebody covers and contacts the second side; and the encapsulated packagebody contacts the first major surface of the semiconductor deviceincluding a corner edge of the semiconductor device adjoining the firstmajor surface and the second side.
 2. The device of claim 1, wherein:the first side is exposed outside of the packaged semiconductor device;and the encapsulated package body encapsulates the conductiveinterconnect structure.
 3. The device of claim 1, wherein: theencapsulated package body covers more than 50% but less than 100% of thefirst major surface of the semiconductor device.
 4. The device of claim1, wherein: the encapsulated package body covers more than 75% but lessthan 100% of the first major surface of the semiconductor device.
 5. Thedevice of claim 1, wherein: the second side of the side surface of thesemiconductor device is an inactive side.
 6. The device of claim 1,wherein: the substrate comprises a second outer side surface opposite tothe first outer side surface; the encapsulated package body comprises afirst package body side surface proximate to the first side of thesemiconductor device; the first package body side surface comprises atapered shape; the encapsulated package body comprises a second packagebody side surface opposite to the first package body side surface; andthe second package body side surface is substantially co-planar with thesecond outer surface of the substrate.
 7. The device of claim 1,wherein: the encapsulated package body comprises an epoxy material. 8.The device of claim 1, wherein: the substrate comprises: an insulatingstructure comprising the first substrate surface and a second substratesurface opposite to the first substrate surface; a conductive patternlayer adjacent to the first substrate surface; conductive lands adjacentto the second substrate surface; and conductive interconnect pathselectrically coupling the conductive pattern to the conductive lands. 9.The device of claim 1, wherein: the first outer side surface of thesubstrate proximate to the first side of the semiconductor devicecomprises a singulated surface; and the first side of the semiconductordevice is positioned over the first substrate surface laterally inwardfrom the singulated surface so that a portion of the first substratesurface is interposed between the first side of the semiconductor deviceand the singulated surface.
 10. A packaged electronic device,comprising: a substrate having a major surface, a first side, and asecond side opposite to the first side; an electronic component coupledto the substrate, the electronic component having a first major surface,a second major surface opposite to the first major surface, and a sidesurface extending between the first major surface and the second majorsurface, wherein the side surface comprises an active surface proximateto the first side of the substrate; a conductive interconnect structureelectrically coupling the electronic component to the substrate; and apackage body encapsulating the conductive interconnect structure,encapsulating at least a portion of the major surface of the substrate,and encapsulating the electronic component, wherein: the active surfaceand a portion of the first major surface of the electronic componentproximate to the active surface are exposed outside of the package body;the electronic component is coupled to the major surface of thesubstrate so that the active surface of the electronic component islaterally inward from the first side so that a portion of the majorsurface of the substrate is interposed between the first side and theactive surface.
 11. The device of claim 10, wherein: the side surface ofthe electronic component comprises an inactive side that is distal tothe active side; the package body contacts the inactive side; and theelectronic component comprises an optical component having an emitteradjacent to the active surface.
 12. The device of claim 10, wherein: thepackage body contacts the electronic device; and the package body coversmore than 50% but less than 100% of the first major surface of theelectronic component.
 13. The device of claim 10, wherein: the packagebody comprises a package body side surface proximate to the activesurface of the electronic component; and the package body side surfacecomprises a tapered shape.
 14. The device of claim 10, wherein: thefirst side of the substrate proximate to the active surface of theelectronic component comprises a singulated surface.
 15. The device ofclaim 10, wherein: the substrate comprises: an insulating structurecomprising the major surface and a second major surface opposite to themajor surface; a conductive pattern layer adjacent to the major surface;conductive lands adjacent to the second major surface; and conductiveinterconnect paths electrically coupling the conductive pattern to theconductive lands; and the electronic component is directly attached tothe major surface.
 16. A method, comprising: providing a substratehaving a major surface; coupling an electronic component to thesubstrate, the electronic component having a first major surface, asecond major surface opposite to the first major surface, and a sidesurface extending between the first major surface and the second majorsurface, wherein the side surface comprises an active surface for theelectronic component; and encapsulating at least a portion of the majorsurface of the substrate and the electronic component with a packagebody to provide a packaged electronic device, wherein at least theactive surface is exposed to an outside of the packaged electronicdevice, wherein: the electronic component comprises an optical device;and a portion of the first major surface of the electronic componentproximate to the active surface is exposed to the outside of thepackaged electronic device.
 17. The method of claim 16, furthercomprising: coupling the electronic component to the substrate, with aconductive interconnect structure, wherein the package body encapsulatesthe conductive interconnect structure.
 18. The method of claim 16,wherein: the package body directly contacts the electronic component;and package body covers more than 50% but less than 100% of the firstmajor surface of the electronic component.
 19. The method of claim 16,wherein: the package body comprises a package body side surfaceproximate to the side surface of the electronic component; and thepackage body side surface comprises a sloped shape.